Bahir Dar University

Bahir Dar Institute of Technology

Faculty of Mechanical and Industrial Engineering
Mechanical Engineering Program

Internship Report
Project Title: Design of manually and electrically operated drilling machine
Hosting Company: Amhara Metal Industry and Machine Technology Development
Enterprise

By: Mebit Fiseha ……………0801011

Mengstu Gedamu………0801056
Nega Endalew…………..0801156
Temesgen Gashaw …….0801316
Mentor: Mr. Gebru Amera
Company Supervisor: Mr. Awole Mohabaw
Sep. 15, 2012 E.C
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Declaration

Our hosting company Amhara Metal Industry and Machine Technology Development Enterprise
(AMITDE) that we have approved our practical skills, theoretical knowledge, interpersonal
communication skills, work ethics and entrepreneurship skills in it. An internship program is the program
that experience gained was approved by both the mentor from the campus (University) and supervisor
from the hosting company (Industries).

Supervisor was assigned to us and he contributed in outwork by training program used for four month that
depends on the activities on subsection of AMITDE Company. In addition to these, command on what
have done material support, improvement of work, and monthly and final evaluation were performed by
him.

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Acknowledgment

Above all we thank GOD for every opportunity we are given in life through its endless mercy, strength
and wisdom in every steps of our life. Secondly we have to extend our greatest gratitude to Bahir Dar
Institute of Technology for providing such kind of opportunity for student to apply their understanding on
how a given work is carried out on their respective field of studies, which in our case Amhara Metal
Industry and Machine Technology Development Enterprise.

Thirdly We would like to express our profound sense to deepest to AMIMTDE, which is willing to
accept our internship program, for valuable guidance, sympathy cooperation for providing necessary
facilities and source during this internship program We wish to register our sincere gratitude to all
AMIMTDE employees.

Finally we would have thanks for our advisor Mr. Gebru Amera to give us a comment and for help us
how to accomplish our task.

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Executive summary

This internship project contains five main chapters with sub topics. The first chapter is about the
background of Amhara metal industry and machine technology development enterprise with its brief
history, main products and services, the main customers, organizational structure, work flow and its
vision and mission. The second chapter represents over all internship experience the problem statement
that have been faced and the proposed solution and also the work task that we executed and consists of
overall conclusion and recommendation about internship period . The third chapter consists of literature
review. The fourth chapter consists that project work, we have been excited a project in order to solve the
company problem and we design manually and electrically operated drilling machine accordingly to the
requirement of the company. Chapter five consists general conclusion, recommendation and over all
reference that we use in internship project.

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Table of contents

Table of Contents
Declaration ................................................................................................................................................................... I
Acknowledgment ......................................................................................................................................................... II
Executive summary...................................................................................................................................................... III
CHAPTER ONE............................................................................................................................................................... 1
1. Company background ....................................................................................................................................... 1
1.1. History of the company ................................................................................................................................. 1
1.2. The main products or service of the company …………………………………………………………………………………………2
1.3. Its main customers or the end users of its products or services ……………………………………………………………..3
1.4. Organizational structure …………………………………………………………………………………………………………………………4
1.5. Work flow ……………………………………………………………………………………………………………………………………………….5
1.6. Machines that are present in the shop ……………………………………………………………………………………………………5

CHAPTER TWO ………………………………………………………………………………………………………………………………………………………8

2. Internship experiences …………………………………………………………………………………………………………………………………8

2.1. Our working section of the company ……………………………………………………………………………………………………….8
2.2. Work tasks ……………………………………………………………………………………………………………………………………………….8
2.3. Engineering methods, tools and techniques we used ………………………………………………………………………………9
2.4. Major challenges and problems facing during internship ……………………………………………………………………….10
2.5. Measurements taken in order to overcome these challenges and problems. ………………………………………..10
2.6. Improving practical skill …………………………………………………………………………………………………………………………11
2.7. Upgrading theoretical skills ……………………………………………………………………………………………………………………11
2.8. Improving team playing skill ………………………………………………………………………………………………………………….12
2.9. Improving leadership skill ……………………………………………………………………………………………………………………..12
2.10. Understanding about work ethics, industrial psychology and related issues……………………………….13
2.11. Improving entrepreneurship skills ……………………………………………………………………………………………..13
2.12. Improving your interpersonal communication skills …………………………………………………………………..14
2.13. Conclusion and Recommendation ……………………………………………………………………………………………..15
2.13.1. Conclusion ………………………………………………………………………………………………………………………………….15
2.13.2. Recommendation ……………………………………………………………………………………………………………………….15

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CHAPTER THREE ………………………………………………………………………………………………………………………………………………..17

3. Literature review …………………………………………………………………………………………………………………………………….17

3.1. Drilling operation ………………………………………………………………………………………………………………………………..17
3.2. Working principle of drill press …………………………………………………………………………………………………………..18
3.3. Work materials …………………………………………………………………………………………………………………………………..18
3.4. Cutting speed, feed, depth of cut, tool wear and tool life …………………………………………………………………..19

CHAPTER FOUR ………………………………………………………………………………………………………………………………………………….21

4. Project work ……………………………………………………………………………………………………………………………………………..21

4.1. design of manually and electrically operated drilling machine ………………………………………………………………21
4.1.1. background of drilling machine …………………………………………………………………………………………………..21
4.1.2. summary of the project ………………………………………………………………………………………………………………21
4.1.3. statement of the problem …………………………………………………………………………………………………………..21
4.1.4. Objective …………………………………………………………………………………………………………………………………….22
4.1.4.1. General objective ……………………………………………………………………………………………………………………22
4.1.4.2. Specific objective ……………………………………………………………………………………………………………………22
4.1.5. Methodology ……………………………………………………………………………………………………………………………..22
4.1.6. Analysis ………………………………………………………………………………………………………………………………………23
4.1.7. Result and discussion …………………………………………………………………………………………………………………42
4.1.8. Recommendation ………………………………………………………………………………………………………………………43

CHAPTER FIVE …………………………………………………………………………………………………………………………………………………..44

5. General conclusion and recommendation ……………………………………………………………………………………………….44

5.1. General conclusion ……………………………………………………………………………………………………………………………..44
5.2. Recommendation ……………………………………………………………………………………………………………………………….44

References ……………………………………………………………………………………………………………………………………………….45

Appendices ………………………………………………………………………………………………………………………………………………46

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List of tables
Table 2.1 summary of weekly report ……………………………………………………...14

Table 4.1 Driving Motor Power …………………………………………………………..24

Table 4.2 Machine Tool Efficiency Factors E ……………………………………………24

Table 4.3 Tool Wear Factors W ………………………………………………………….25

Table 4.4 Power Constants KP……………………………………………………………25

Table 4.5 Formulas for Calculating the Metal Removal Rate, Q…………………….……25

Table 4.6 Recommended values for drilling ..……………………………………………..26

Table 4.7 Feed Factors, C, for Power Constants……………………………………….….26

Table 4.8 Number of teeth at velocity ratio…………………………………………….…29

Table 4.9 Characteristics of roller chains according to ISO……………………………....30

Table 4.10 Mechanical properties of steels used for shafts…………………………….....32

Table 4.11 principal dimensions for radial ball bearing………………………………......36

Table 4.12 Dimensions of standard V-belts according to IS………………………...……37

Table 4.13 estimated cost analysis ………………………………………………………..41

Table 4.14 result …………………………………………………………………..………42

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List of figures
Fig 1.1 Organizational structure of AMIMTDE ……………………………………………..4

Fig 1.2 Work Flow of AMIMTDE …………………………………………………………5

Fig 1.3 lathe machines In AMIMTDE ……………………………………………………..5
Fig 1.4 Milling machines In AMIMTDE ………………………..……………………..…..6
Fig 1.5 CNC gas cutting machine In AMIMTDE …………………………………………...6
Fig 1.6 Shearing Machines in AMIMTDE ……………………………………………..……6
Fig 1.7 Shearing and Trimmer Machines in AMIMTDE ……………………………………7
Fig 1.8 Hydraulic bending machines in AMIMTDE ………………………………………...7
Fig 1.9 Machine Shop ………………………………………………………………………..7
Fig 1.10 Metal Shop ………………………………………………………………………….7
Fig 2.1 Wrenches ……………………………………………………………………………..9
Fig 2.2 screw driver ………………………………………………………………………….10
Fig 2.3 Ratchets, extension &sockets ………………………………………………………..10
Fig 4.1 geometrical analysis …………………………………………………………………23
Fig 4.2 chain drives …………………………………………………………………………..28
Fig 4.3 sprocket ………………………………………………………………...…………….28
Fig 4.4 shaft ………………………………………………………………..…………………32
Fig 4.5 key ……………………………………………………………..……………………..33
Fig 4.6 Clamp or compression coupling …………………………..…………………………35
Fig 4.7 ball bearing …………………………………………………………………………..35
Fig 4.8 fly wheel ………………………………………….………………………………….36
Fig 4.9 belt drive …………………………………………………………………………….36
Fig 4.10 rack and pinion ……………………………………………………………………..38
Fig 4.11 frame with bar ………………….…………………………………………………..40
Fig 4.12 seat …………………………………………………………………………………40
Fig 4.13 plot feed lever ………...……………………………………………………………41

VII
 CHAPTER ONE
1. Company Background
1.1 History of company
Amhara Metal Industry and Machine Development Technology Enterprise (AMIMDTE) is located in the
capital of Amhara regional state, Bahir Dar, Ethiopia. The company established in 1985 by the name of
Bahir Dar Rural Technology Promotion Center with the aim of multiplying of and popularizing
agricultural implements, rural industry development and rural energy development team. But after 1996,
after the center has been re-organized with the objective of supporting the sustainability of the agricultural
development in the region through design, testing and promoting agricultural implements. During this
time it was rearranged in prototype design and studies and production and maintenance team. Finally in
1999 the name of the center changed to Bahir Dar Agriculture mechanization and Food Science research
center and started to conduct research on generating/selecting, developing, adopting and promoting
appropriate agricultural mechanization technologies at the regional level.

Bahir Dar Agricultural Mechanization & Food Research Center, (BAM&FSRC) undertakes problem
oriented agro-ecology based research on pre-harvest and irrigation technologies, post-harvest handling
and processing technologies and alternative energy technologies for developments , testing and
popularization of need based farm implement and machinery to increase productivity of land labor
through timelines of operations efficient use of inputs , improvements in quality of product, safety and
comfort of farmers as well as reduce drudgery.[1]

The major activities include:-

 Adaptation of agricultural technologies to the mandated areas

 Agricultural technology generation
 Promotion of agricultural technologies in collaboration with other research departments and other
stakeholders in the region and outside the region.
Recently, in 2008, the Bahir Dar Agricultural mechanization & Food Science Research Center is
organized into Metal Industry and Machine Technology Development Enterprise.
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The purpose of this enterprise is to reduce the regional state demand, supply and utilization shortage with
in production industry and agricultural investment and to meet the regional goal in industrial translation
with in overall market.

The core activities of the company which is apply in following specialized area:-

1, In the General tools product

4, Agricultural tools product

2, Electrical tools product

5, Construction tools product

3, Transport tools

6, Food machining tools and others

Currently the Enterprise is starting to manufacture different types of technological products by the two
existed well organized workshops found at Bahir Dar and Kombolcha city (Amhara region).

Vision of the company;

 To be one of the best top 10 technology center in Africa since 2017 E.C.
Mission of the company;

 To create metal and machine technology development market center.

 To solve problems related to agricultural and industrial technology.
 To develop competitive industries in the world that sustains continuous technology
development.
 To reduce foreign currency by reversing machines

1.2 The main products or service of the company

This enterprise has many products and services that are produced according to the customer needs and
orders.

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Considering the problems that are facing our region currently, this company basically produces the
following products;

1. Transportation instruments

2. Electrical instruments

3. Heavy machineries and mining instruments

4. Agricultural instruments

5. Petrochemical and general instruments

6. Measuring tools

7. Internal combustion engine

8. Machine tool and tool industry

9. Tools used for keeping environmental sanitation

10. Food packaging instruments

Services given by the company includes;

 Counseling and training services

 Installation, commissioning and maintenance services

 Machine specification preparation

 Spare parts production and selling

 Metal and machine technology manufacturing and selling

1.3 Its main customers or the end users of its products or services
The main end users of its products are:-

 Farmers
 Fishers
 Researchers

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 Comminutes
 Universities
 Privet sectors
 Different factories
 Agricultural research

1.4 Organizational structure

The structure of the enterprise seems as follows:-[1]

Fig: 1.1. Organizational structure of AMIMTDE

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1.5 Work flow

Fig: 1.2. Work Flow of AMIMTDE[1]

1.6. Machines that are present in the shop

1) Lathe machine
Lathe is one of the most versatile and widely used machine tools all over the world. It is commonly
known as the mother of all other machine tools. The main function of a lathe is to give the materials
required shape and size.

Fig:1.3. lathe machines In AMIMTDE

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2) Milling machine
Milling is a machine that the metal or work piece is cut by means of a rotating cutter having multiple
cutting edges. For cutting operation, the work piece is fed against the rotary cutter. As the work piece
moves against the cutting edges of milling cutter, metal is removed in the form of chips. There are
different types of milling cutters.

Fig:1.4. Milling machines In AMIMTDE

3) CNC gas cutting machine

CNC cutting machine is operated with acetylene gas which used to cut different shapes such as, curve
circle and ellipse.

Fig: 1.5. CNC gas cutting machine In AMIMTDE

4) Shearing machine and fish polarizer

Shearing machine is used to cut sheet metals by shearing action whereas; fish platizer is used to mix food
of fishe.

Fig: 1.6.Shearing Machines in AMIMTDE

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Fig: 1.7. Shearing and Trimmer Machines in AMIMTDE

Fig: 1.8. Hydraulic bending machines in AMIMTDE

Workshops in AMIMTDE

Fig: 1.9. Machine Shop

Fig: 1.10. Metal Shop

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CHAPTER TWO

2. Internship experiences
2.1 Our working section of the company
This enterprise has commonly different sections. Some of them are:-

 Industrial Design team

 Agricultural team
 Financial team
 Product quality checking team
 Assembly team
 Work shop
Among those teams we have been working under the design and manufacturing team; why because, when
the managers grouped in different sections they considering on our stream. Therefore we are participating
in both team.

2.2 Work tasks

Reverse engineering is a systematic methodology for analyzing the design of an existing device or
system, either as an approach to study the design or as a prerequisite for re-designs. It develops a
systematic approach to thinking about the engineering design of devices and systems. Acquire a mental
data bank of mechanical design solutions.

Solid Works is a mechanical design automation software package used to build parts, assemblies and
drawings that takes advantage of the familiar Microsoft Windows graphical user interface.

We have been executing under reversing the customer ordered products by the help of solid work
software.IN addition to this we have actively participate in workshop like:-

 Welding
 Machining
 Drilling
 Bar cutting and bending
 Sheet metal shearing, etc.

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2.3. Engineering methods, tools and techniques we used

Methods, tool & techniques are vital to the success of any project.

Method: - is way of doing something in a systematic way. Here “systematic” implies an orderly logical
sequence of steps or task. .

Technique is a specific approach to efficiently accomplish a task in a manner that may not be immediately
obvious.

In this section, all work tasks are performed according the standard instruction manuals formulated by
Company. And these guidelines contain many mechanical engineering methods and techniques.

Some of the mechanical engineering techniques and methods are: Benchmarking (prepare standard),
Design of experiments, Employee Involvement, Equipment Utilization, Flow diagramming, Information
and data flow diagramming, Interviewing for Information, Lean Manufacturing, Modeling and Testing,
Operations auditing, Plant and equipment layout, Project management, Strategic Planning, Theory of
Constraints, Time Studies, Work Sampling

Tools: some of the tools that we have been used are:-

 Caliper
 Meter
 Allen key
 Adjustable wrench
 Open wrench
 Hand tools

(a).Open end wrenches (b). Closed end wrenches (c) Combination wrenches
Fig: 2.1. Wrenches

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Figure 2.2 screw driver

Figure 2.3 Ratchets, extension &sockets

2.4 Major challenges and problems facing during internship

The challenges and problems that we have faced during intern practice are:-

 Since all the machinists in the shop are engaged full of time there is no enough time
to practice on machines.

 Lack of computer access to do individual task.

 Have no safe working area to do within team. i.e. they do not give us the machine to
practice with group when the machine is free.
 Lack of information which accomplish measuring the parts to change into solid work
modeling.
 Didn’t get permission to disassemble the machine as soon as we finish our practice.
 Have no comfortable place to set each component easily. Like, table or shelf.

2.5 Measurements taken in order to overcome these challenges and problems.

Measurements that we have taken to overcome those challenges:-

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 Even if the machinists engaged full of time we follow them actively all the working
processes while they are doing different structures; like gear, pulley, bolt and nut, tread,
slot etc.
 By exchanging measuring tools from one group to another group.
 By holding the machine parts from the shop to outside.
 By dividing tasks and doing them in group.
 By asking advice from the engineers.
2.6 Improving practical skill
We know how to give attention for ever thing what we have doing.

And we have been trying just to know new things in order to get new practical knowledge. in machine
installation; we gain that how machine is install and different installation requirement to prevent the
machine from any failure. And we have got a chance to disassemble and assemble different machines; and
also we recognize the working mechanism of those machines.

We have been familiar for solid works soft ware and design and modeling of different machine part using
solid work. This is the base to design any machine and prepare flow chart for manufacture process.

2.7 Upgrading theoretical skills

In internship program we have get the opportunity to apply my theoretical knowledge in real world
environments. Frankly speaking, my theoretical knowledge got strengthen more by those practical
techniques invested on this internship.

This internship period was a good filed to read about real world problems how to solve it in engineering
departments. Therefore, we gained the following essential things:

 Creative and logical approach to solving problems

 The ability to analyze and approach difficult works
 Clearly understand different machine devices working principle and mechanism
 We have also acquired more knowledge about design, installation and manufacturing
 Upgrading our knowledge to solve problems such as; agricultural and industrial problems
 We have develop our knowledge on design and modeling of different machine part using solid
work

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2.8 Improving team playing skill

Team work has a dramatic effect on one’s organizational performance. An effective team can help the
organization to achieve goals. We have understood that team work is an essential thing to solve problem
and nothing is impossible when we work together. Team work also helps us to strength our
communication skill and to generate different ideas which can solve various challenging problems.
Generally, our team playing skill helps us to improve the following qualities:

 To communicate constructively
 To be active participant
 Cooperate and help others
 To tolerate differences
 Showing commitment to the team
 to overcome difficult problems
2.9 Improving leadership skill
Leadership is a process of leading the careers of the company. Thus a person who is in the position of
leadership seeks optimal solution to problems and should be smart enough to manage those individuals
whom he/she is leading. In this internship program, we think we partly void the bad image we had for the
leaders. We were brought in a society who thinks the leadership as stand for power and dominance over
the other and his/her benefit only. Therefore, we were not accustomed to thinking of leaders as servants
and we were giving special respect for them.

By now, leadership to us; is a person who sought his time, energy for his people with a profit of
satisfaction and it is art of inspiring others to give of their best. Generally During the internship period
with respect to leadership skills we have learned and convicted to have the following attributes to be
successful leader:

 General intelligence, to make sense of the complexity and difficulty of the task.
 Technical or professional knowledge and competence in their particular fields is often the bedrock
of respect for leaders.
 Personality - leaders should be energetic and committed, maintain contact with their people, and
understand their strengths and weaknesses.
 The ability to:-
 Know our self and seek self-improvement

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 Be technical proficient
 Seek responsibility and take responsibility for actions
 Make sound and timely decisions
 Develop sense of responsibility in workers
2.10 Understanding about work ethics, industrial psychology and related issues
Ethical work enables us to posses’ appropriate behaviors in the work and so we developed proper
relationship with coworkers and it enables us to create good working environment. The following are the
common professional ethical principle what we are gaining during the internship period:

Punctuality- means keeping the companies work beginning and ending time and to complete a given task
within a given period

Office discipline-in work place you should not disturb the working environment for example; abstain
from opening loud voice, loud music, songs and things which disturb other worker’s working mood

Reliability-the workers should be qualified for part he is supposed to be performing

Honesty-regarding this value each worker regardless of its status should abstain from bad behavior such
as; cheating, bias and corruption.

2.11 Improving entrepreneurship skills

We have gained wide range of skills of entrepreneurship during internship period. These include both
personal traits and skills:

 Management skills-the ability to manage time, money and people(both our self and
others)successfully
 Communication skills and the ability to sell ideas and persuade others
 The ability to form our own business starting from small and simple thing. Most machines of the
company are made up of local row materials
 Self-motivated and disciplined
 Adaptable
 Innovative thinking and creativity
 Able to take responsibility and making of fair decision
 The ability to work overtime and over load

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Willingness to take responsibility

 Ability to make wide network in business

 Able to plane for the feature
 To know one business is profitable or not
2.12. Improving your interpersonal communication skills
We are also improving our interpersonal communication skill. The purpose of communication is to get
our message across to others clearly and without ambiguity. Inability to communicate with office mates
makes it nearly impossible to compute effectively in the work place and sharing constructive ideas and to
generate new and difference ideas which are very important for creative nesses.

Generally, without smooth communication with coworkers there is no satisfactory success on our job. We
have got the following basic experiences from our internship period.

 How to communicate with people operating on machines and shops

 How to express ideas freely accordingly
 How to communicate with people w0orking in different companies
 Improve communication during team work which is very important; We had improved our
interpersonal communication skill by presenting different questions and suggestions for:-
 company employees
 group members
 managers
Table 2.1 summary of weekly report
 months Weeks Weekly report

March Week one (16 -22)  Introduction to the

company background
and its structure.
Week two(23 -29)  set a time schedule to
practice solid work
software and
introduction to features
April Week one(30 -6)  start 2D drawing
practicing ( solid work)
 worksheet practicing

Week two(7 -13)  start 3D modeling

practicing
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 worksheet practicing
Week three(14 -20) assembling and sheet
metal practicing(solid
work)
Week four(21 -27) o ------
May Week one(28 -4)  No work at all but the
students are arranged
For different shop
Week two (5 -11)  Overview of the whole
shop

Week three(12-18)  Welding shop practicing
 Machine shop practicing
Product produced:- gear,
pulley, shaft, screw, crank
holder rod, key
Week four(19-25)  Wood shop practicing

June Week one(26 -2)  Project work

Week two(3 -9)
Week three(10 -16)
Week four(17 -23)

2.13 Conclusion and Recommendation

2.13.1 Conclusion
To conclude our internship practice ; It can be considered as the way for interns to prepare or ready
ourselves for real practical world both in technical and social perspectives and also it produces skilled
man power not only ideally but also practically. Internship program has great importance in order to
create educated as well as entrepreneur man power. The longer the time of internship, the more will be the
experiences and advantages. This importance is not only experience in technical aspect, but also in social
communication and reaction, developing taking responsibility, experience of leadership and team work.

2.13.2 Recommendation

During the internship practice we recommended that all machinist in the company works as they want.
But they should wear all the safety clothes and materials. In addition to this in the company all the cutout

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metals are thrown carelessly everywhere; but it is better to collect all the thrown metals in a certain place.
If it is possible it may be re-melt to reduce material waste.

We would like to give valuable recommendation for the company; to fulfill the necessary safeties for
internship students, to be willing to give information about the company except secrets, and to fulfill
enough instruments and measurements.

Finally, what we recommend here is that the intern student and the company relation should be
cooperative. But company supervisor are not let the intern student to do what and how he/she works in the
company as expected.

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CHAPTER THREE
3. Literature review
Machining is the removal of the unwanted material (machining allowance) from the work piece (WP), so
as to obtain a finished product of the desired size, shape, and surface quality. The practice of removal of
machining allowance through cutting techniques was first adopted using simple handheld tools made from
bone, stick, or stone, which were replaced by bronze or iron tools. Water, steam, and later electricity were
used to drive such tools in power-driven metal cutting machines (machine tools). The development of new
tool materials opened a new era for the machining industry in which machine tool development took
place. Nontraditional machining techniques offered alternative methods for machining parts of complex
shapes in hard, stronger, and tougher materials that are difficult to cut by traditional methods. Drilling
allied or alternative operations such as core drilling, center drilling, counter boring, countersinking, spot
facing, reaming, tapping, and other operations can also be performed on drilling machines. Accordingly,
the main and feed motions are the same as in drilling; that is, the drill rotates while it is fed into the
stationary work piece. In these processes, the tool shape and geometry depend upon the machining
process to be performed.[3]

3.1. drilling operation

Operation of the portable electric and pneumatic drills differs from recommended operating procedures
for the upright drilling machine. The portable drill is hand supported for most operations, and the cutting
speed of the drill is fixed or dependent upon the operator to control. When hand supported, the drill must
be carefully aligned with the work piece and this alignment must be maintained throughout the drilling
operation. Care must be taken not to lose control of the portable drill and allow it to be wrenched from the
operator’s hands. The larger portable drills can be very dangerous if not held firmly by the operator. If the
cutting speed is fixed, the operator must learn to control the feed of the portable drill by applying
sufficient pressure for the drill to cut, but not too much pressure as to cause overheating of the twist drill
or stalling of the portable drill motor. When metal is to be drilled with the portable drill, the work piece
must be prepared by locating the center position of the potential hole and marking the location with a
center punch. When a large drill is to be used, it will be necessary first to drill a pilot hole slightly larger
in diameter than the thickness of the larger drill’s web, which will allow for the drag caused by the larger
drill’s chisel edge portable pneumatic drills require special attention to lubricate their internal moving

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parts. Each drill may be made slightly different, so refer to the pertinent lubrication order or
manufacturer’s instruction manual before drilling.[8]

3.2. Working principle of drill press

Successful operation of the drill press requires the operator to be familiar with the machine and the
desired operation. The following are some good observations to follow when drilling a hole:

 Prior to drilling a hole, locate the hole by drawing two crossing lines. Use a center punch to make
an indentation for the drill point to aid the drill in starting the hole.
 Select the proper drill bit according to the size needed.
 Select an appropriate size center drill.
 Select a cutting fluid.
 Properly secure the work piece to the table.
 Select the correct RPM for the drill bit. Take into account: size of bit, material, and depth of hole
to be drilled.
 Use an interrupted feed, called peck drilling, to break up the chips being produced.
 Pilot holes should be used on holes larger than 3/8” dia. Holes are to be enlarged in no more than
1/4” increments.
 Clean the drill press and surrounding area when finished.
Hard and fast rules are not always practical for every operation performed in a drill press, since
many factors can influence the speed and feed at which a material can be worked. The above
suggestions, combined with knowledge of the tool being used, will provide a reasonable guideline
for the operator using a drill press.

3.3. work materials

The large numbers of work materials that are commonly machined vary greatly in their basic structure and
the ease with which they can be machined. Yet it is possible to group together certain materials having
similar machining characteristics, for the purpose of recommending the cutting speed at which they can be
cut. Most materials that are machined are metals and it has been found that the most important single
factor influencing the ease with which a metal can be cut is its microstructure, followed by any cold work
that may have been done to the metal, which increases its hardness. Metals that have a similar, but not

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[AMIMDTE 2011 E.C

necessarily the same microstructure, will tend to have similar machining characteristics. Thus, the
grouping of the metals in the accompanying tables has been done on the basis of their microstructure.

Non-ferrous Metals:

We have already discussed that the non-ferrous metals are those which contain a metal other than iron as
their chief constituent. The non-ferrous metals are usually employed in industry due to the following
characteristics:

 Ease of fabrication (drilling, casting, rolling, forging, welding and machining),

 Resistance to corrosion,
 Electrical and thermal conductivity, and
 Light in weight.
The various non-ferrous metals used in engineering practice are aluminum, copper, lead, tin, Non-
metallic Materials: - non-metallic materials are used in engineering practice due to their low
density, low cost, flexibility, resistant to heat and electricity. Though there are many nonmetallic
materials, yet the following are important from the subject point of view.
1. Plastics. The plastics are synthetic materials which are molded into shape under pressure with or
without the application of heat. These can also be cast, rolled, extruded, laminated and machined.
Following are the two types of plastics:
(a) Thermosetting plastics, and
(b) Thermoplastic.

3.4. Cutting Speed, Feed, Depth of Cut, Tool Wear, and Tool Life
The cutting conditions that determine the rate of metal removal are the cutting speed, the feed rate, and
the depth of cut. These cutting conditions and the nature of the material to be cut determine the power
required to take the cut. The cutting conditions must be adjusted to stay within the power available on the
machine tool to be used. Power requirements are discussed in Estimating Machining Power later in this
section. The cutting conditions must also be considered in relation to the tool life. Tool life is defined as
the cutting time to reach a predetermined amount of wear, usually flank wear. Tool life is determined by
assessing the time the tool life at which a given predetermined flank wears is reached (0.01, 0.015, 0.025,
0.03 inches, for example). This amount of wear is called the tool wear criterion, and its size depends on
the tool grade used. Usually, tougher grade can be used with a bigger flank wear, but for finishing

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[AMIMDTE 2011 E.C

operations, where close tolerances are required, the wear criterion is relatively small. Other wear criteria
are a predetermined value of the machined surface roughness and the depth of the crater that develops on
the rake face of the tool.

Cutting speed formula:

Tool Wear and Tool Life Relationships

Tool wear tool-life is defined as the cutting time to reach a predetermined wear, called the tool wear
criterion. The size of tool wear criterion depends on the grade used; usually a tougher grade can be used at
bigger flank wear. For finishing operations, where close tolerances are required, the wear criterion is
relatively small. Other alternative wear criteria are a predetermined value of the surface roughness, or a
given depth of the crater which develops on the rake face of the tool. The most appropriate wear criteria
depend on cutting geometry, grade, and materials. Cutting tool is maintained daily per any operation drill
bit is maintained by sharping the tip of the drill bit by using grinding with in standard helix angle.

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[AMIMDTE 2011 E.C

CHAPTER FOUR
4. project work
4.1 design of manually and electrically operated drilling machine
4.1.1 Background of drilling machine
Drilling is a process used extensively by which through or blind holes are originated or enlarged in a work
piece. This process involves feeding a rotating cutting tool along its axis of rotation into a stationary work
piece. The axial feed is usually very small when compared to the peripheral speed. Drilling is considered
a roughing operation and, therefore, the accuracy and surface finish in drilling are generally not of much
concern. If high accuracy and good finish are required, drilling must be followed by some other operation
such as reaming, boring, or grinding. The most commonly employed drilling tool is the twist drill, which
we can drill in diameters ranging from 3 to 20 mm. Drilling allied or alternative operations such as core
drilling, center drilling, counter boring, countersinking, spot facing, reaming, tapping, and other
operations can also be performed on drilling machines. Accordingly, the main and feed motions are the
same as in drilling; that is, the drill rotates while it is fed into the stationary work piece. In these
processes, the tool shape and geometry depend upon the machining process to be performed.[3]

4.1.2 summary of the project

This drilling machine is dual operated with in both electrical and human power and fitted with a drill bit
used for drilling holes in various materials the drill bit rotated while cycling the pedal or when electrical
motor is attached to driving shaft and the tip of the cutting tool does work cutting material by using
drilling chuck and rotating lever to drilling press work piece in to the target point of drilling and power is
transmitted by using combination of belt and roller chain drives. It is drill piece of material made of metal,
wood, PVC and operated by electrical power to drill nonferrous metals and when it is operated by human
power it is drill some soft material made of metal, wood, PVC therefore it can be used in areas was
electricity is insufficient or irregular and. It is used for small scale workers who can work in their work
shop and simplistic in design operation and handling.

4.1.3 statement of the problem

Drilling without drilling machine is difficult operation in local workshop and in manufacturing
industries drilling machine is not available in all work shop and it is expensive it needs electric power and
operated by skilled person only those problems are cause:
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 Drilling is difficult operation

 Cost of the drilling machine is maximum relative to manually drilling machine
 Drill machine must need only electrical power
 In most rural area there is no electric power and drilling without drill machine is difficult for
agricultural tool material, house hold tools and transportation material
 Most of traditional agricultural tool materials are joined by drilling the material in traditional
method, example chisel hammer drilling.
4.1.4 Objective
4.1.4.1 General objective

The main objective of this project is to design manually and electrically operating
drilling machine.

4.1.4.2 Specific objective

 To design the machine that available within low cost and simply operate
 To design and model parts,
 To specify human and electric power for safe working condition
 To give awareness about importance and application of this machine for local
people
 To fabricate this machine with minimum cost in local work shop if there is any
Sponsor.

4.1.5 Methodology
To successfully work on this project different methods of analysis are used. From the methods
used the main ones are listed below as follows:
 Data collection through directs observation the current machine working facture
and referring to some books and handouts related to the study, using journal
reference.
 Select simple mechanism and drilling operation
 Design by considering operation and machine ergonomics for safe working
Condition
 Literature survey and internet browsing in order to carefully analyze the work
 Proper design based on effective design

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[AMIMDTE 2011 E.C

4.1.6 Analysis
Geometry analysis

Fig.4.1 geometrical analysis

Assumption data:
Average cycling for human 80rpm
Human force 150 – 200N
Overall length of the machine 1.46m
Over all height of the machine 1.8m
Radius of the pedal foot 30cm

Drill diameters ranging from 0.25 to 20 mm.

The standard helix of a twist drill is 30°, which, together with a point angle of 118°, is suitable for
drilling steel and CI. Drills with a helix angle of 20°, known as slow-helix drills, are available with a
point of 118° for cutting brass and bronze, and with a point of 90° for cutting plastics. Quick helix
drills, with a helix angle of 40° and a point of 100°. [7]

Driving Power

P=FxV
P=Pedaling power for human
F = Minimum human force is 150N-200N this machine is operating by maximum Human force
200N there is also fly wheel for speed increment when operators lower the cycling
V= cycling speed when pedal cycling by average is N= 80rpm

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[AMIMDTE 2011 E.C

V= = =1.256m/s

Power=force x velocity
P=200N x 1.256m/s= 251.2watts

Then this power is sufficient to drill wooden material, soft metals and PVC material the, power to drill
wooden material is less than 251watts.

 The power also increase by means of fly wheel it is freely rotating and store energy when
the pedal is cycling more the stored energy is transmitted from fly wheel to chain drive ,
belt drive, spindle and drill bit.
 This power is drill soft material like nonferrous metal, wooden materials, PVC material and etc [4]

Table 4.1 Driving Motor Power[5]

Table 4.2 Machine Tool Efficiency Factors E[5]

Pc [kW] = Kp [kW/ cm3/s] ×C×Q [cm3/s] ×W

Where: Pc= power at the cutting tool; HP, or kW

Kp= power constant, HP/ in3/min or kW/ cm3/s
Q = metal removal rate; in3/min. or cm3/s
C = feed factor for power constant
W = tool wear factor

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[AMIMDTE 2011 E.C

Table 4.3 Tool Wear Factors W[5]

Table 4.4 Power Constants KP[5]

Table 4.5 Formulas for Calculating the Metal Removal Rate, Q[5]

Where Q = Removal Rate, VC= cutting speed, d = depth of cut, f = feed rate
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[AMIMDTE 2011 E.C

Table 4.6 Recommended values for drilling[5]

Table 4.7 Feed Factors, C, for Power Constants[5]

Pc [kW] = Kp [kW/ cm3/s] ×C×Q [cm3/s] ×W

 W= tool wear factor when type of drilling is normal drilling =1.30. From table 4.3
 Kp= power constant, HP/ in3/min or kW/ cm3/s, for Aluminum cast…Kp= 0.25 HP/
in3/min KP= 0.68 kW/ cm3/s, for Aluminum rolled hard= Kp= 0.33 HP/ in.3/min, KP=
0.90 kW/ cm3/s. From table 4.4
Q = metal removal rate; in3/min. or cm3/s

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[AMIMDTE 2011 E.C

Q = Removal Rate, VC= cutting speed, d = depth of cut, f = feed rate

VC=16feet/min, VC=16m/min, f= 0.008in, f=0.2mm d = depth of cut is depend on thickness of

work piece for 20mm for maximum removal rate. From table 4.6
For Inch Units Only Q = 12 VCf d= 12 x 16feet/min x 0.008in x 1.575in= 2.42in3/min for minimum
cutting speed in feet/min (16feet/min)
For SI Metric Units Only Q = VCf d/60= (1600cm/min x0.02cm x 2cm)/60= 1.06cm3/s for
minimum cutting speed in feet/min (16m/min)
C is feed factors, f or Power Constants. From table 4.7 [5].

C is feed factors, for Power Constants=1.08

Driving Motor Power in [kW]
Pc [kW] = KP [kW/ cm3/s] ×C×Q [cm3/s] ×W
Pc [kW] = 0.68[kW/ cm3/s]×1.08×1.06[cm3/s]×1.3=1.01kw
Pm =

Pm = = 1.25KW where E is 0.9 for direct and belt drive

Driving speed
Formulas for calculating the rotational speed N [RPM] [5]

N= Rotation speed in [RPM]

V= cutting speed 377feet/min from table 4.6
D = drill bit diameter in inches or mm [0.25 to 20mm] maximum drilling diameter is 20mm=0.78in
N= = 1847 1850 rpm

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[AMIMDTE 2011 E.C

Driving Motor Torque

Formulas f or calculating of Driving Motor torque[5]

Tm= = = 6452NM

Chain drive

Fig 4.2 chain drives

1. Velocity Ratio of Chain Drives
The velocity ratio of a chain drive is given by:

The normal function of a chain sprocket is not only to drive or be driven by the chain, but also to guide and
support it in its intended path.

Sprockets are usually of 3 main types.

 One piece sprockets of steel or cast iron.

 Two pieces split sprockets.
 Sprockets with bolt-on-tooth segments.
Number of teethes on the smaller sprocket. [2]

Figure 4.3 sprocket

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[AMIMDTE 2011 E.C

Table 4.8 Number of teeth at velocity ratio

Number of teethes on the smaller sprocket is 23 from table 4.8.

Assume number of teeth on the larger sprocket is double of number of teethes on the smaller sprocket then
number of teeth on the larger sprocket is 46 Speed of motor = 1850rpm (is driving speed).

Velocity Ratio of Chain Drives:

V.R1 =
V.R1 = =2

The second velocity ratio V.R then let the maximum speed reduced by quarter, and the second by triple, and
the third by half, then number tooth the number of tooth of pinion is T1=23 T2=46, T3=92, T4= 69, T5=23

Then velocity ratio VR1=2, VR2=4, VR3= 3, VR4=1

The maximum allowable speed for chains is equal with speed of the motor= 1850rpm.
Speed ratio=
=462rpm

=616rpm

=1850rpm
2. The design power by using the service factor

From driving power transmitted by chain 1.25kw

Rated power=1.25kw

Such that Design power = Rated power × Service factor

= P x KS

KS= Service factor = K1.K2.K3

The service factor (KS) is the product of various factors, such as load factor (K1), lubrication

factor (K2) and rating factor (K3). The values of these factors are taken as f ollows:
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[AMIMDTE 2011 E.C

1. Load factor (K1) = 1, for constant load

= 1.25, for variable load with mild shock

= 1.5, for heavy shock loads

2. Lubrication factor (K2) = 0.8, for continuous lubrication

= 1, for drop lubrication

= 1.5, for periodic lubrication

3. Rating factor (K3) = 1, for 8 hours per day

= 1.25, for 16 hours per day

= 1.5, for continuous service

Where K1=1.25, K2= 1.5 K3=1 KS=1.25 1.5 1=1.875

Design power = Rated power × Service factor

= 1.25kw× 1.875

=2.34kw

Table 4.9 Characteristics of roller chains according to ISO[2]

Characteristics of roller chains is depend on power and speed of chain for low speed and low power (ISO
Chain number 06B) then Pitch (p) mm=9.325, Roller diameter (d1)mm Maximum= 6.35, Width between
Inner plates (b1)mm Maximum=5.72 transversal pitch (p1)mm=10.24, breaking load for simple 7.8KN.

3. Determine the load (W) on the chain

W= =v=
We know that pitch circle diameter of the smaller sprocket or pinion

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[AMIMDTE 2011 E.C

d1=pcosec = 9.325cosec = 9.325x7.98= 273.57mm=0.27357m

Pitch circle diameter of the larger sprocket
d2=9.325cosec = 9.325x482=450mm=0.045m
d3=9.325cosec = 9.325x820=760mm=0.76m
d4 = 9.325cosec = 0.55m
V= = 1.7m/s.
W= = 735N
4. The factor of safety by dividing the breaking load (WB)
Factor of safety = = = 10.6
 Factor of safety is high because chain is possible transmit maximum power up to 110 kW this
machine is transmit minimum power, chains drive be used for long centre distance of up to 8
meters. The chains are also used for velocities up to 25 m / s.
5. Centre distance between the sprockets
 The minimum centre distance for the velocity transmission ratio of 3, may be taken as:
X= + 30 to 50mm Where d1 and d2 are the diameters of the pitch circles of the smaller
and larger sprockets.
 For best results, the minimum centre distance should be 30 to 50 times the pitch.
 The minimum centre distance is selected depending upon the velocity ratio so that the arc of
contact of the chain on the smaller sprocket is not less than 1200. It may be noted that larger angle
of arc of contact ensures a more uniform distribution of load on the sprocket teeth and better
conditions of engagement.
X= + 30 to 50mm

But for long center distance from geometrical analysis the length of the machine is 1.46m by consideration
of distance between the sprockets. Center distance between two sprockets.

X1 = + 30 = 0.86m …………. For horizontal chain

X2 = + 50 = 1m ………………. for vertical chain

6. Length of the chain

For vertical chain the length of the chain (L) must be equal to the product of the number of chain links (K)
and the pitch of the chain (p). Where x is centre distance mathematically,

L=K.p

The number of chain links may be obtained from the following expression,

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[AMIMDTE 2011 E.C

K= ]2

2
K=

L=K.p =180x9.325mm=3676mm= 3.676 m for both horizontal and vertical chain .

For horizontal chain the length of the chain (L) must be equal to the product of the number of chain links
(K) and the pitch of the chain (p). Where x is centre distance mathematically, L=K.p

K= ]2

K= [ ]

L=K.p =157x9.325mm=2102mm= 2102m for both horizontal and vertical chain.

Shaft
A shaft is a rotating machine element which is used to transmit power from one place to another.

Fig.4.4 shaft

Table 4.10 Mechanical properties of steels used for shafts[2]

From types of material we select designation no. 45 C 8 ultimate tensile strength 650 MPa and having Yield
strength of 350 MPa.

Diameter and length determination

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[AMIMDTE 2011 E.C

To calculate the diameter we use the moment and rpm value of the wheel.

So the given parameters are:-design power=1250watts

N=1850RPM

Torque = = = 6452NM

To get the diameter we use the following formula:-

T= D3 for shafts Subjected to Twisting Moment Only

Where, τ = shear stress of the shaft, we get from ultimate strength of the material is

equal to 0.18 ultimate stergth

=117MPA

D=diameter of the bar or connecting rod or shaft.

D3 = = = 27041.4mm3

D =√ mm = 30mm

Key way
There are two basic function of the key the primary function of key is to transmit the torque from the shaft
to the of mating element and vice versa the second function of key is to prevent relative motion between the
shaft and the joined machine element like gear, pulleys, and wheels in most of cases key also prevent axial
motion between two element.[2]

Fig.4.5 key

The usual proportional of key is

W=d/4 t=2w/t or d/6

W= width of the key

t =thickness of the key

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[AMIMDTE 2011 E.C

d=diameter of the key

Where d is shaft diameter d=30mm from shaft design

w=d/4,30/4=7.5mm

t=2w/3=d/6 =30/6=5mm

w=width of the key = 7.5mm

t=thickness of the key = 5mm

 We know that the maximum torque transmitted by the shaft T=6452NM

T= L× w× t× d1/2 where d1 is shaft diameter and w is width of key

Taking t= 400 MPa = 400N/mm2 from key material

6455x103Nmm=L x 7.5mm x 400N/mm2 x 30mm/2

6455x103Nmm =90000L

L=71.7mm is length of key

Shaft coupling
Shaft Coupling: - Shafts are usually available up to 7 meters length due to inconvenience in
transport. In order to have a greater length, it becomes necessary to join two or more pieces of the
shaft by means of a coupling but in this machine the power transmission shaft is short but the power
is transmitted from motor to chain drive by means of short shaft motor shaft and chain drive shaft
the two shaft are connected by coupling. Shaft couplings are used in machinery for
several purposes, the most common of which are the following;
1. To provide for the connection of shafts of units that is manufactured separately such as
a motor and generator and to provide for disconnection for repairs or alternations.
2. To provide for misalignment of the shafts or to introduce mechanical flexibility
3. To reduce the transmission of shock loads from one shaft to another.
4. To introduce protection against overloads.
5. It should have no projecting parts.

Flexible coupling: - It is used to connect two shafts having both lateral and angular
misalignment. Following types of flexible coupling are important from the subject point of view
(a) Sleeve or muff coupling.
(b) Clamp or split-muff or compression coupling, and
(c) Flange coupling
This machine shaft are connected by flexible coupling because the machine is operated by both
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[AMIMDTE 2011 E.C

motor and human power when the machine is operated by motor, motor shaft and transmission
shaft is connected by coupling and in other case when the machine is operated by human power
transmitted shaft is directly connected with pedal(two coupling).
The usual proportions of the muff for the clamp or compression coupling are:
Diameter of the muff or sleeve, D=2d+ 13 mm
Length of the muff or sleeve, L= 3.5 d
Where d= Diameter of the shaft.

Figure 4.6 Clamp or compression coupling.

Diameter of the muff or sleeve, D=2d+ 13 mm
D=2 x 30mm + 13 mm = 73mm
Length of the muff or sleeve, L= 3.5 d
L= 3.5 x 30 = 105mm
Design for bolt Nominal diameter for bolts db= Root or core diameter of bolt.
T= 𝑥 𝜏 𝑥 d3
6455NM= 𝑥 𝜏 𝑥 d3
where τ allowable shear stress 𝜏=400N/mm2, coupling material is the same with keys material.
d= √33 mm = 15.2mm
db= 15 mm we find that the standard core diameter of the bolt for coarse series is 18 mm and the
nominal diameter of the bolt is 18mm (M 18).
Bearing selection
Bearing is used to rotate the wheel structure for these application we use radial ball bearing having the
following standard dimensions’ from table 4.11 ………………….Bearing no. 206

Bore diameter= 30mm

Outside diameter =62mm

Width of bearing= 16 mm

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[AMIMDTE 2011 E.C

Fig.4.7 Ball bearing

Table 4.11 principal dimensions for radial ball bearing.[2]

Fly Wheel

Fly wheel in this machine is used to increase human power when, when we cycling the pedal within chain
power transmitted to this wheel it is increase the power by storing energy.

 Diameters of the wheel: 609mm, 660mm, and 685mm are common. Teeth on the chain wheel 24 to
58, Teeth on the rear sprocket 12 to 38. For this machine diameter of the wheel is 660mm, teeth on
the chain wheel 40, teeth on the rear sprocket 30 . [6]

Fig.4.8 flywheel

 This wheel is also available in the market for specified dimension.

Belt and pulley

Fig.4.9 belt drive

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[AMIMDTE 2011 E.C

V-belt is more preferable for drilling machine used in the rural area-belt is used where a great amount of
power is to be transmitted from one pulley to another when the two pulleys are very near to each other. The
material of the belt must be strong flexible and durable .it must be have high coefficient of fiction so The V-
belts are made of fabric and cords molded in rubber and covered with fabric and rubber.

Table 4.12 Dimensions of standard V-belts according to IS: 2494 – 1974.[2]

From the above table it is better to take type a belt.

Thickness (t) =8 mm
Top width (b) =13mm
Coefficient of friction =0.28
The angle of grove on a pulley(2B)=400
Weight per meter length =1.06N/m
Permissible shear stress =42 mpa
Center distance between pulley =600mm
Density of pulley = 1200kg/m3

The length of the belt can be calculated by using the following formula:-
( )
L= π(r2 + r1) + 2x + Where:-r2=radius of pulley no 2 from table
r1 =radius of pulley no one
Then r1=r2=37.5mm
X= center distance between two pulley
X=600mm
L= (37.5+37.5) +2(600) + = 2035.5mm
From standard length of type a v- belt take length of belt 2068mm.
To get the inside length of the belt subtract 36mm from length of belt for type A belt.
Inside length of belt =2068-36=2032mm
Checking failurity of belt by power

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[AMIMDTE 2011 E.C

The pulley is attached to the chain drives they have the same no of revolution (rpm) when velocity
ratio is one and also the two pulleys are the same diameter. So N1=N2= 1850rpm and d1 =d2=75mm
Since the belt is open belt.

= Where:-r1 and r2 are the radius of two pulley

X is the center distance between two pulleys

Then = =0 α=00

Angle of lap, =1800 -2α =1800

Velocity of the belt = ………………..V = = 14.52m/s

Centrifugal tension (TC) = mv2

TC = 1.06(14.52)2 = 223N
The pulley for v-belt uses aluminum for better economic efficiency and strength, having better
mechanical property tensile strength and easily manufacture.

A Rack and Pinion

A Rack and Pinion is composed of two gears, a Rack and Pinion arrangement is used to lift vice or work
piece holding device. The flat helical gear is the rack and the round helical gear is the pinion. The rack has
teeth cut into it and they mesh the teeth of the pinion gear. Also a spur gear is connected to the shaft of the
pinion a rack and pinion is used to convert between rotary and linear motion.

Fig.4.10 Rack and pinion

Rack-Cast iron= <390 N/mm²

Pinion-Cast iron= =30 N/ mm²

Specification of Rack

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[AMIMDTE 2011 E.C

Material- Cast iron

Module =1.5mm

Cross section= (58×25) mm2

 Basic Dimensions Rack:

L=284mm

L1=L+35(grinding allowance)

L1=284+38=319mm

 Number of Threads on Rack = = = 21

 Actual Length of Rack = 21 x π x 5 = 330mm

Specification of Pinion:

Material-Cast iron Addendum=1.5mm

Outside diameter=58mm Dedendum=1.8m

Pitch circle diameter=55mm Circular tooth thickness=2.35mm

Circular pitch=4.7mm Fillet radius=0.45mm

Pressure angle=21° Clearance=0.

Frame
Frame is used to carry the machine, and used to housing chain and belt drives attached by welding to
another frame. For these application is gray cast iron is selected.

St Designation FG150
Having tensile strength=150mpa
Compressive strength 600mpa
Height of the vertical frame=1.8m (only for vertical)
Length of the bar =1.8m
Diameter of the hollow bar =10cm
Thickness of the hollow bar=10mm
Length of the horizontal frame 1.45m

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[AMIMDTE 2011 E.C

Width of the frame = 40cm

Thickness of the frame = 5mm
Frames used to support weight of the machine and housing for chains and belt drives.

Fig.4.11 frame with bar

Seat
When the machine is operated by human power the man is seat on chair. The dimension of the

chair is according to human factor and ergonomics .

Height of the chair = 70cm

The width of the chair = 40cm

Fig.4.12 seat

The chair is made from wood or metal may joined by welding, rivet or screw fasteners and it is may fixed
on floor or frame. To make it comfortable during working fixing soft material on top of seat this may same
as bicycle seat.

Drill Press
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[AMIMDTE 2011 E.C

Drill Press is one of the most frequently used machine tools. They are used mainly for drilling holes but
reaming, countersinking, and boring can also be accomplished with the drill press. Most machine shops are
equipped with at least one pedestal-type drill press. These machines are used to drill holes in wood, plastic,
aluminum, brass, and most other common engineering materials. Injuries on this equipment generally arise
from careless operation by users who fail to take the time to clamp their work to the table or who try to hold
the drill press vise in one hand while advancing the spindle in the other.[3]

Fig.4.13 Pilot Feed Lever

 Feed lever the Feed Lever is used to raise and lower the spindle.

Table 4.13 Estimated Cost analysis

When we calculate the cost of material we should know the current price and we must select the lower cost
with appropriate properties. Secondly we consider the material price only not others like design, operator
cost, labor, transportation etc

Material selection [7]

no Component name Material quantity Per unit birr Total birr

1 Shaft Mild steel 4 200 800
2 Roller chain Alloy steel 2 600 1200
3 Sprocket Cast iron 4 130 520
4 Bearing Bronze 8 150 1200
5 Belt Rubber 1 150 150
6 Pulley Aluminum 2 200 400
7 Rack Alloy steel 1 400 400
8 Pinion Alloy steel 1 130 130
9 Drill bit HSS 1 240 240
10 Key Nickel 6 110 660
11 Coupling Rubber 2 85 170
12 Bolt, nut and pin Carbon steel 1 250 250
13 Frame Cast iron 3 1000 3000
14 Flywheel Steel 1 1200 1200
15 Seat Wood 1 300 300
Total cost 10370

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4.1.7 Result and discussion

Table 4.14 Result

no Component name Quantity Dimension(mm)

Length Diameter Width thickness
1 Belt 1 2068 13 8
2 Chain 2 2101 6.25 5.72
3 Rack 1 330 2.35
4 Pinion 1 58 2.35
5 Shaft 4 500 30
6 Smaller sprocket 2 273.57
7 Larger sprocket 2 450
8 Flywheel 1 660
9 Pulley 2 75 20
10 Frame 2 1800 40 5
11 Seat 1 700 400

Power speeds torques and another specification of the machine:

Driving power (motor power) = 1.25Kw
Driving power (Motor speed) = 1850rpm
Driving power for human = 251watts
Average cycling for human = 80rpm
Overall length of the machine = 1.46m
Over all height of the machine = 1.8m
Radius of the pedal foot = 30cm
Centre distance between two horizontal sprockets = 0.86m
Centre distance between two vertical sprockets = 1m
Drill diameters ranging from 0.25 to 20 mm

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Discussion
The above results are the basic design parameters of drilling machine that are used to assemble or
manufacture industries local work shop and in rural area. when we compare the given power to machining
power of non-ferrous material such as the driving power is greater than machining power constant and The
dimensions each components are based on the design calculation and the standards of the component from
the standard tables and The above amount of revolution per minute is safe for these drilling machine and also
the power and speed required is safe when we compare and calculate from the machining power and speed
constant of properties of non-ferrous material.

4.1.8. Recommendation
We recommend to all manufacturing sectors and rural people, use this machine to get better revenue and
from drilling operation, it is most suitable for rural people drilling agricultural toolmaterial, house hold or
transporting material is better than for traditional drilling method. This machine also designed by based on
low cost also rural capital.

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CHAPTER FIVE
5. General conclusion and recommendation
5.1. General conclusion
Generally this machine is one of recommended types of machine in manufacturing industries and for
people in rural area it is used to get better revenue from drilling operation in rural area and indirectly
better to come up sustainable development in the world from the manufacturing sector. This machine drill
different work piece by electrically and manually, only one person can operate this machine at both
electrically and manually operating time, It can drill different types of material changing the speed ratio,
by use gear ratio to change the speed it is like bicycle gear shifting mechanism, in this design considering
different things and targeting on material that it drills is important thing, The performance of the machine
depends on the driving power condition. It is required appropriate driving power and speed of the motor
and human cycling speed and driving power.

5.2 Recommendation
Our recommendation for the internship students and the company is that they should be work cooperatively
with positive attitudes.
Firstly every student should have good relationship for the whole company workers as much as possible from
labor to the manager to get a reliable and a solid knowledge as well as information for our project.
Secondly on the company side they should give special attention to the students by indicating the problems
and by giving direction on the started project.
Next to this, this project not applicable for hard materials. So any one should work on such problem.

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REFERENCES
[1] Company workshop manual document

[2] R.S KHURMI and J.K GUPTA. Text Book of Machine Design, Eurasia publishing house (PVT) ltd
2005

[3] Production engineering fifth edition. New York: McGraw-Hill, ISBN 007-252036-1

[4] http://www.google.com short history of pedal operated drilling machine

[5] Engineering-Reference-Information PDF

[6] Ken Hurst. Engineering Design Principles: I SBN: Publisher: Elsevier Science & Technology Books
0340598298, Pub. Date: May 1999

[7] Mikell P.Groover. Fundamentals of Modern Manufacturing: materials, processes and systems. 4th ed.

[8] http://www.google.com drilling operation

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Appendices

7
8 6
5

9 4

10
2

11

Main components of the manually and electrically operated drilling machine

No Name of component quantity

1 Pedal 1
2 Chain 2
3 Seat 1
4 Vice 1
5 Chuck 1
6 Pulley 2
7 Belt 1
8 Shaft 4
9 Rack and pinion 1
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10 Flywheel 1
11 Sprocket 4

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